Fluid level sensing apparatus and method for a spray applicator

ABSTRACT

The present invention relates to a level sensing spray applicator. In one embodiment, the spray applicator includes a gun that receives a liquid and a supply vessel coupled to the gun. The vessel includes a level sensor responsive to the volume retained by the supply vessel. In another aspect, a level-sensing supply vessel includes a level sensor responsive to a volume of liquid retained by the supply vessel, the sensor including a sensor element to detect the volume by sensing a resistance property of the liquid. In still a further aspect, a method of sensing a level of a liquid retained within a storage vessel includes sensing a first liquid volume, removing a portion of the first volume to define a second volume, determining if the second volume is less than a minimum volume, and generating an alarm signal if the second volume is less than the minimum volume.

TECHNICAL FIELD

The present invention relates generally to equipment for applying aliquid to surfaces, and more particularly, to fluid level sensing for aspray applicator device.

BACKGROUND OF THE INVENTION

A wide variety of spray application devices for applying liquids such aspaint, varnish, cleaning solvents, or other liquid materials to asurface are known. Typically, such spray applicator devices include asupply vessel that contains a volume of the liquid to be applied to thesurface. The liquid is transferred from the supply vessel to a spray gunthat atomizes the liquid and projects the atomized liquid towards thesurface. In one example of a spray applicator device, the supply vesselis positioned above the spray gun so that the liquid is transferred tothe spray gun by a gravity-feed system. In another example of anapplicator device, the supply vessel may be positioned below the spraygun and internally pressurized to transfer the liquid upwardly into thegun. In still other examples, the vessel may be positioned remotelyrelative to the gun so that the liquid is transferred from the vessel tothe spray gun through a flexible hose.

In all of these spray applicator devices, determining the volume of theliquid remaining in the supply vessel as the application of the liquidproceeds constitutes a significant problem. If the liquid volume in thesupply vessel is reduced to a low value, the gun may be supplied withliquid only intermittently, so that the gun emits the atomized liquid onan interrupted basis. As a consequence, the spray applicator devicefails to apply the liquid uniformly to the surface. In particular, whenthe spray applicator device is used to apply a paint material to asurface, surface imperfections in the paint finish may result whennon-atomized paint is projected, or “sputtered” onto the surface, thusnecessitating time consuming surface rework and re-painting. Sincesupply vessels commonly used with spray guns are comprised of materialsthat are substantially non-transparent, a visual indication of theliquid level in the supply vessel is not generally possible.

Accordingly, there is a need in the art for a level-sensing device forspray applicators to provide a user of the spray applicator with anaudible or visual indication when the volume of liquid in the supplyvessel has been reduced to a predetermined level.

SUMMARY OF THE INVENTION

The present invention relates generally to a spray applicator device forapplying a liquid to surfaces, and more particularly, to a fluid levelsensing apparatus and method for a spray applicator device. In oneaspect, a spray applicator apparatus includes a gun configured toreceive a liquid and atomize the liquid, and a supply vessel coupled tothe gun. The supply vessel retains a volume of the liquid and includes alevel sensor responsive to the volume retained by the supply vessel. Inanother aspect, a level-sensing supply vessel for a spray applicatorincludes a level sensor responsive to a volume of liquid retained by thesupply vessel, the sensor including a sensor element configured todetect the volume by sensing a resistance property of the liquid. Instill a further aspect, a method of sensing a level of a liquid retainedwithin a storage vessel of a spray applicator includes sensing a firstvolume retained within the vessel, removing a portion of the firstvolume to define a second volume, determining if the second volume isless than a predetermined minimum volume, and generating an alarm signalif the second volume is less than the predetermined minimum volume.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial diagrammatic view of a spray applicator according toan embodiment of the invention.

FIG. 2 is a schematic view of a control system for a spray applicatorhaving a level sensor according to an embodiment of the invention.

FIG. 3 is a is a schematic view of a control system for a sprayapplicator having a level sensor according to another embodiment of theinvention.

FIG. 4 is a partial cross-sectional view of a supply vessel for a sprayapplicator having a level sensor according to another embodiment of theinvention.

FIG. 5 is a partial cross-sectional view of a supply vessel for a sprayapplicator having a level sensor according to still another embodimentof the invention.

FIG. 6 is a partial cross-sectional view of a supply vessel for a sprayapplicator having a level sensor according to still yet anotherembodiment of the invention.

FIG. 7 is a cross sectional portion of a sensor element according tostill yet another embodiment of the invention.

FIG. 8 is a partial cross-sectional view of a supply vessel for a sprayapplicator having a level sensor according to a further embodiment ofthe invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is generally directed to equipment for applyingliquid coating materials to surfaces, and in particular, to fluid levelsensing for a spray applicator. Many of the specific details of certainembodiments of the invention are set forth in the following descriptionand in FIGS. 1-8 to provide a thorough understanding of suchembodiments. One skilled in the art will understand, however, that thepresent invention may be practiced without several of the detailsdescribed in the following description. Moreover, in the descriptionthat follows, it is understood that the figures related to the variousembodiments are not to be interpreted as conveying any specific orrelative physical dimension. Instead, it is understood that specific orrelative dimensions related to the embodiments, if stated, are not to beconsidered limiting unless the claims expressly state otherwise.

FIG. 1 is a partial diagrammatic view of a spray applicator 10 accordingto an embodiment of the invention. The spray applicator 10 includes asupply vessel 12 that contains a volume of a liquid 14. A spray gun 16is coupled to the supply vessel 12, and transfers the liquid 14 to thespray gun 16 so that an atomized spray pattern may be developed at anozzle 18. As the spray pattern is emitted from the gun 16, the liquid14 retained within the supply vessel 12 is gradually depleted, so that asurface level of the liquid 14 gradually descends as the sprayingoperation is conducted. Operational details of the spray gun 16 are wellknown in the art, and need not be discussed in further detail. Althougha gravity-feed type spray applicator is shown in FIG. 1, it isunderstood that the various embodiments of the present invention mayalso be employed in other types of spray applicators, and are thereforenot limited to the spray gun shown in FIG. 1. For example, the supplyvessel 12 may be positioned below the spray gun 16, or alternately maybe located remotely from the spray gun 16 so that the liquid 14 istransferred to the spray gun 16 by a flexible hose, or other similardevices (not shown).

Still referring to FIG. 1, the spray applicator 10 further includes asensor element 20 that extends into the liquid 14 within the supplyvessel 12. The sensor element 20 is configured to allow an electricalresistance property of the liquid 14 to be measured that corresponds toa volume of liquid 14 retained within the vessel 12. For example, whenthe volume of liquid 14 defines a first level 22 within the supplyvessel 12, a first resistance quantity may be measured by the sensorelement 20. As the volume of the liquid 14 is gradually reduced todefine a relatively lower intermediate level 24, a second resistancequantity that differs from the first resistance quantity may be read bythe sensor element 20. As the level of the volume of the liquid 14 isreduced still further to define a second level 26, so that the sensorelement 20 is no longer immersed in the liquid 14, the sensor element 20ceases to measure a resistance quantity related to the liquid 14, sothat only a resistance property related to the sensor element 20 ismeasurable. The sensor element 20 will be described in further detailbelow.

A control system 28 is operatively coupled to the sensor element 20. Thecontrol system 28 includes circuitry that is configured to measureelectrical resistance quantities sensed by the sensor element 20, and tooutput a control signal when a predetermined resistance quantity ismeasured. Referring now to FIG. 2, a particular embodiment for thecontrol system 28 of FIG. 1 is shown. The control system 28 includes avoltage source 30 that is selectively coupled to a current-sensingnetwork 32 by a switch 34. The system 28 is coupled to the sensorelement 20, which has a resistance value (R_(L)) that depends upon thevolume of the liquid 14 retained by the supply vessel 12, as previouslydescribed. With the switch 34 closed, the system 28 is energized andcurrent flows in the resistance R_(L). The current-sensing network 32measures a current flowing in the control system 28 and generates anoutput signal 36 when a predetermined current level corresponding to apredetermined volume of the liquid 14 is reached. In order to adjustablycontrol the current flowing in the system 28, a potentiometer 38 may beserially coupled to the sensor element 20. In an alternative particularembodiment, the potentiometer 38 may be coupled in parallel with thesensor element 20.

Turning now to FIG. 3, another particular embodiment for the controlsystem 28 of FIG. 1 is shown. In this embodiment, the control system 28includes a current source 40 that is selectively coupled to avoltage-sensing network 42 by the switch 34. The system 28 is coupled tothe sensor element 20. With the switch 34 closed, the system 28 isenergized and a constant current flows in the resistance R_(L). Thevoltage-sensing network 42 measures a voltage across the resistanceR_(L) and generates an output signal 36 when a predetermined voltagecorresponding to a predetermined volume of the liquid 14 is reached. Toadjustably control the voltage appearing across the resistance R_(L), apotentiometer 38 may be serially coupled to the sensor element 20. Instill another alternative particular embodiment, the potentiometer 38may be coupled in parallel with the sensor element 20.

Returning to FIG. 1, the control system 28 is coupled to an alarm device29 that is configured to emit an alarm indication when a suitable outputsignal 36 is received from the control system 28. In one specificembodiment of the invention, the alarm device 29 may be a visual alarmdevice, such as an incandescent light bulb, light emitting diode (LED),or other similar devices that illuminate when the output signal 36 isreceived. In another specific embodiment, the alarm device may be anaudible alarm device, such as a piezoelectric speaker device, or othersimilar device capable of emitting acoustic energy that may be perceivedby an operator of the spray applicator 10. The alarm device 29 may alsoinclude a source of electrical energy to energize the audible or visualalarm device, or alternately, the alarm device 29 may receive electricalenergy from the electrical energy source located within the controlsystem 28.

The operation of the spray applicator 10 will now be described indetail. Still referring to FIG. 1, the supply vessel 12 on the sprayapplicator 10 is supplied with an initial volume of the liquid 14 thatdefines the first level 22. At this point, the sensor element 20 sensesa first resistance quantity corresponding to the initial volume of theliquid 14. Since the sensed first resistance quantity corresponds to asupply vessel 12 that contains a suitable amount of the liquid 14, thecontrol system 28 does not generate an output signal 36 (as shown inFIGS. 2 and 3) so that the alarm device 29 does not generate an audibleor visual signal. As the liquid 14 is drawn from the supply vessel 12,the volume of the liquid 14 decreases to the second level 26, so that adifferent resistance quantity is sensed. Since the sensor 20 is nolonger exposed to the liquid 14, the output signal 36 is generated bythe control system 28 in response to the different resistance quantity.Accordingly, the alarm device 29 generates the audible or visual alarmthat alerts the operator of the spray applicator 10 that the liquid 14in the supply vessel has been depleted. Although the foregoing describesthe output signal 36 as generated when the supply vessel 12 issubstantially depleted, it is understood that the control system 28 maybe configured to generate the output signal 36 when the volume of liquid14 has decreased to a value that is intermediate between a full and adepleted state. For example, and referring still to FIG. 1, the controlsystem 28 may be configured to generate the output signal 36 when thevolume of liquid 14 falls to the intermediate level 24.

FIG. 4 is a partial cross sectional view of the supply vessel 12 of FIG.1 that shows a sensor element 50 according to another embodiment of theinvention. The sensor element 50 includes a first electrode 52 and asecond electrode 54 that is spaced apart from the first electrode 52.The first electrode 52 and the second electrode 54 are comprised of anelectrically conductive material, and are structured to extend through awall of the supply vessel 12 and to extend downwardly into the liquid 14within the supply vessel 12. In order to electrically isolate the firstelectrode 52 and the second electrode 54 from the wall of the supplyvessel 12, insulators 56 are interposed between the first electrode 52,the second electrode 54 and the wall of the supply vessel 12. The firstelectrode 52 and the second electrode 54 may further include extendedportions 58 to permit the sensor element 50 to be coupled to the controlsystem 28.

FIG. 5 is a partial cross sectional view of the supply vessel 12 of FIG.1 that shows a sensor element 60 according to still another embodimentof the invention. As in the previous embodiment, the sensor element 60includes a first electrode 62 and a second electrode 64 that is spacedapart from the first electrode 62. The first electrode 62 and the secondelectrode 64 are similarly comprised of an electrically conductivematerial, and positioned adjacent to the wall of the supply vessel 12and spaced apart from the wall by respective insulating layers 63 and65. The first electrode 62 and the second electrode 64 are electricallyisolated from the wall of the supply vessel 12 by insulators 56 thatextend through the wall of the supply vessel 12. The first electrode 62and the second electrode 64 also may include extended portions 58 topermit the sensor element 50 to be coupled to the control system 28.

FIG. 6 is a partial cross sectional view of the supply vessel 12 of FIG.1 that shows a sensor element 70 according to still yet anotherembodiment of the invention. The sensor element 70 includes a firstelectrode 72 and a second electrode 74 that are formed on an insulatingsubstrate 76 that extends downwardly into the supply vessel 12.Referring briefly to FIG. 7, a cross sectional portion of the sensorelement 70 is shown along the section line 7-7 of FIG. 6. The firstelectrode 72 and the second electrode 74 may be formed from a relativelythin and electrically conductive foil that is cladded onto theinsulating substrate 76. The substrate 76 may be comprised of agenerally rigid, nonconductive material such as a rigid polymer. Thesensor element 70 is suspended within the liquid 14 by an insulatingsupport means (not shown) that is coupled to the wall of the supplyvessel 12. As in the previous embodiments, the first electrode 72 andthe second electrode 74 may be coupled to the control system 28 byextended portions 58 that project through the wall of the supply vessel12.

FIG. 8 is a partial cross sectional view of the supply vessel 12 of FIG.1 that shows a sensor element 70 according to a further embodiment ofthe invention. The sensor element 70 includes an electrode 82 formedfrom an electrically conductive material, which extends downwardly intothe supply vessel 12 and is spaced apart from the wall of the supplyvessel 12. Instead of an electrode that opposes electrode 82, as in theprevious embodiments, the wall of the supply vessel 12 forms anelectrode opposite the first electrode 62. The first electrode 82 iscoupled to the control system 28 by an extended portion 58 that extendsthrough the wall of the supply vessel 12, and is electrically insulatedfrom the wall by an insulator 56. The supply vessel 12 is also coupledto the control system 28 by a lead 84 that is conductively coupled tothe supply vessel 12.

From the foregoing it will be appreciated that, although specificembodiments of the invention have been described herein for purposes ofillustration, various modifications may be made without deviating fromthe spirit and scope of the invention. For example, certain featuresshown in the context of one embodiment of the invention may beincorporated into other embodiments as well. Accordingly, the inventionis not limited by the foregoing description of embodiments except as bythe following claims.

1. A spray applicator, comprising: a gun configured to receive a liquidand atomize the liquid; and a supply vessel coupled to the gun thatsupplies the liquid to the gun, the supply vessel defining a volume forreceiving liquid and including a level sensor responsive to an amount ofliquid within the supply vessel, the level sensor including a firstelectrode and a second electrode mounted to insulating materialpositioned at a perimeter of the volume.
 2. The spray applicator ofclaim 1, wherein the level sensor further includes a sensor element thatextends into the supply vessel, the sensor element being configured todetect a liquid volume by sensing a resistance property of the liquid.3. The spray applicator of claim 1, wherein the level sensor furtherincludes a control system coupled to the supply vessel that generates asignal when a predetermined liquid volume is retained in the supplyvessel.
 4. The spray applicator of claim 3, wherein the level sensorfurther includes an alarm device coupled to the control system toreceive the signal and generate an alarm indication.
 5. The sprayapplicator of claim 2, wherein the sensor element further comprises: afirst electrode; and a second electrode spaced apart from the firstelectrode.
 6. The spray applicator of claim 5, wherein the firstelectrode and the second electrode are positioned adjacent to a wall ofthe supply vessel, the first electrode and the second electrode beingspaced apart from the wall of the supply vessel by an insulating layerinterposed between the wall and the first and second electrodes.
 7. Thespray applicator of claim 5, wherein the first electrode and the secondelectrode are formed on opposing sides of an insulating substrate. 8.The spray applicator of claim 5, wherein the supply vessel furtherincludes a wall that comprises one of the first electrode and the secondelectrode.
 9. The spray applicator of claim 3, wherein the controlsystem includes a current-sensing network coupled to a voltage source.10. The spray applicator of claim 3, wherein the control system includesa voltage-sensing network coupled to a current source.
 11. Alevel-sensing supply vessel for a spray applicator, comprising: a levelsensor responsive to a volume of a liquid retained by the supply vessel,the sensor including a sensor element configured to detect the volume bysensing a resistance property of the liquid.
 12. The level-sensingsupply vessel of claim 11, wherein the level sensor further includes acontrol system coupled to the supply vessel that generates a signal whena predetermined liquid volume is retained in the supply vessel.
 13. Thelevel-sensing supply vessel of claim 12, wherein the level sensorfurther includes an alarm device coupled to the control system toreceive the signal and generate an alarm indication.
 14. Thelevel-sensing supply vessel of claim 11, wherein the sensor elementfurther comprises: a first electrode; and a second electrode spacedapart from the first electrode.
 15. The level-sensing supply vessel ofclaim 14, wherein the first electrode and the second electrode arepositioned adjacent to a wall of the supply vessel, the first electrodeand the second electrode being spaced apart from the wall of the supplyvessel by an insulating layer interposed between the wall and the firstand second electrodes.
 16. The spray applicator of claim 14, wherein thefirst electrode and the second electrode are formed on opposing sides ofan insulating substrate.
 17. The spray applicator of claim 14, whereinthe supply vessel further includes a wall that comprises one of thefirst electrode and the second electrode.
 18. The spray applicator ofclaim 12, wherein the control system includes a current-sensing networkcoupled to a voltage source.
 19. The spray applicator of claim 12,wherein the control system includes a voltage-sensing network coupled toa current source.
 20. A method of sensing a level of a liquid retainedwithin a storage vessel of a spray applicator, comprising: sensing afirst volume of the liquid retained within the vessel by determining afirst resistance value of the liquid; removing a portion of the firstvolume to define a second volume within the storage vessel; determiningif the second volume is less than a predetermined minimum volume bydetermining a second resistance value of the liquid and comparing thefirst resistance value to the second resistance value; and generating analarm signal if the second volume is less than the predetermined minimumvolume.
 21. (canceled)
 22. (canceled)
 23. The method of claim 20,wherein generating an alarm signal further comprises generating anaudible alarm.
 24. The method of claim 20, wherein generating an alarmsignal further comprises generating a visual alarm.
 25. The method ofclaim 20, wherein removing a portion of the first volume to define asecond volume further comprises expelling the portion through a spraygun coupled to the supply vessel.